CN112059363A - Unmanned wall climbing welding robot based on vision measurement and welding method thereof - Google Patents
Unmanned wall climbing welding robot based on vision measurement and welding method thereof Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J5/00—Manipulators mounted on wheels or on carriages
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/02—Seam welding; Backing means; Inserts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/24—Features related to electrodes
- B23K9/28—Supporting devices for electrodes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/24—Features related to electrodes
- B23K9/28—Supporting devices for electrodes
- B23K9/287—Supporting devices for electrode holders
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/32—Accessories
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J11/00—Manipulators not otherwise provided for
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J9/00—Programme-controlled manipulators
- B25J9/16—Programme controls
- B25J9/1679—Programme controls characterised by the tasks executed
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
- B25J9/00—Programme-controlled manipulators
- B25J9/16—Programme controls
- B25J9/1694—Programme controls characterised by use of sensors other than normal servo-feedback from position, speed or acceleration sensors, perception control, multi-sensor controlled systems, sensor fusion
- B25J9/1697—Vision controlled systems
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Abstract
The invention discloses an unmanned wall climbing welding robot based on visual measurement and a welding method thereof, wherein the robot comprises a main vehicle system and an auxiliary vehicle system, the main vehicle system is adsorbed on the inner wall of a workpiece to be welded in an operation space, welding seam information of a binocular visual navigator, a laser visual sensor and a visual detection unit is obtained through a miniature industrial personal computer, and the miniature industrial personal computer controls a multi-degree-of-freedom mechanical arm to move a welding gun to weld the wall climbing of the workpiece to be welded in different curved surface areas; the auxiliary vehicle system obtains position information of the main vehicle system through the vision module, controls the auxiliary vehicle system to follow the main vehicle system through the miniature industrial personal computer, controls the multi-degree-of-freedom mechanical arm of the main vehicle system to move, and provides power and cooling liquid for the welding gun. The invention solves the problems that the existing arc welding robot can not meet the welding requirement of the production environment of non-standard products, can not adapt to the deformation and the inconsistency of workpieces in the welding process and the welding quality is not high due to the deviation of self weight from the welding track.
Description
Technical Field
The invention belongs to the technical field of welding robots, and particularly relates to an unmanned wall climbing welding robot based on vision measurement and a welding method thereof.
Background
With the application of welding automation, the welding of large structural parts is increasing, and arc welding robots are widely applied in the production environment of standardized products, such as manufacturing industries of automobiles, engineering machinery and the like. However, in the non-standard product production environment, such as large oil tanks, ships, pressure pipelines and the like, because the welding surface is a curved surface and the welding difficulty is high, the existing arc welding robot cannot meet the requirements and needs manual welding operation by field workers; meanwhile, the labor intensity of workers is high, the environment is severe, multiple workers are required to complete the operation in a cooperative mode, the requirement on welding is high, and the production rate is low. The fundamental reasons are that: the existing arc welding robot has a small working range, and although the working range of the existing arc welding robot can be expanded by using the seventh axis, the existing arc welding robot has poor flexibility and still cannot meet the actual use requirement. In addition, the existing arc welding robots are generally teaching-type, and the teaching itself needs a considerable amount of work and cannot adapt to the situation that the deformation and the workpiece itself are inconsistent in the welding process.
The climbing welding robot has high requirement on load, so that the adsorption force is increased, the load is increased, and the motion flexibility of the robot is deteriorated due to the increased load; meanwhile, the load also causes a certain offset when the robot walks in the horizontal direction, which is not beneficial to the rapid adjustment of the welding posture of the robot. At present, wall-climbing welding robots on the market all adopt a remote controller to combine a mode of manually identifying welding seams for welding, so that the welding quality cannot be guaranteed, and the production efficiency is low.
Therefore, the wall climbing welding robot which is highly unmanned and flexible and can accurately position and guide the welding robot to reach the specified welding seam position is developed, and the wall climbing welding robot has important significance in the wall climbing welding robot industry.
Disclosure of Invention
In order to solve the defects in the prior art, the invention aims to provide the unmanned climbing welding robot based on vision measurement, and the unmanned climbing welding robot has the characteristics of unmanned, accurate positioning, high automation and high flexibility and can adapt to the welding of curved surfaces made of magnetic conductive materials.
The invention is realized by the following technical scheme.
The embodiment of the invention provides an unmanned wall climbing welding robot based on vision measurement, which comprises a main vehicle system and an auxiliary vehicle system, wherein:
the main vehicle system is adsorbed on the inner wall of a workpiece to be welded in an operation space, welding seam information of the binocular vision navigator, the laser vision sensor and the vision detection unit is obtained through the miniature industrial personal computer, and the miniature industrial personal computer controls the multi-degree-of-freedom mechanical arm to move the welding gun to weld the workpiece to be welded in wall climbing in different curved surface areas;
the auxiliary vehicle system acquires position information of the main vehicle system through the vision module, controls the auxiliary vehicle system to follow the main vehicle system through the miniature industrial personal computer, controls the multi-degree-of-freedom mechanical arm of the main vehicle system to move, and provides power and cooling liquid for the welding gun.
With respect to the above technical solutions, the present invention has a further preferable solution:
preferably, the main vehicle system comprises a binocular vision navigator, a multi-degree-of-freedom mechanical arm, a vision detection unit, a wire feeder, a wire disc, two groups of high-precision code discs, two groups of laser vision sensors and a miniature industrial personal computer; the binocular vision navigator, the multi-degree-of-freedom mechanical arm, the wire feeder, the wire disc, the miniature industrial personal computer, the two groups of laser vision sensors A and B are arranged on a climbing frame of the main vehicle, and the climbing frame of the main vehicle is erected on a driving wheel; the laser vision sensor A and the laser vision sensor B are respectively arranged at the front end and the rear end of the climbing frame of the main vehicle and face vertically downwards, and the driving wheels are controlled by a micro industrial personal computer.
Preferably, the visual detection unit is arranged on the multi-degree-of-freedom mechanical arm, and the two groups of high-precision code discs A and B are respectively arranged on the driving wheel; the binocular vision navigator and the multi-degree-of-freedom mechanical arm are fixed at the tail end of the chassis of the climbing frame of the main vehicle through locking screws.
Preferably, the auxiliary vehicle system comprises an auxiliary vehicle frame, a welding machine, a cooling water tank, a wire feeding barrel, a vision module, an electric permanent magnetic chuck, a flexible magnetic material and a mechanical arm control cabinet; the welding machine, the cooling water tank, the wire feeding barrel and the mechanical arm control cabinet are all fixed at the top of the auxiliary vehicle frame, and the vision module is installed at the bottom of the auxiliary vehicle frame; the side wall of the auxiliary vehicle frame is coated with flexible magnetic conductive material.
The embodiment of the invention further provides a welding method of the climbing welding robot, which comprises the following steps:
and 4, repeating the steps 1 to 3, and finishing the welding process of the unmanned wall climbing welding robot based on the vision measurement.
Preferably, the specific operation steps of step 1 are as follows:
11) the binocular vision navigator carries out denoising and filtering preprocessing on the acquired surrounding space environment image information, identifies key characteristic points of the current position of the preprocessed image, extracts pixel coordinates of the characteristic points, utilizes internal parameters of the binocular vision navigator to solve the space coordinates of the characteristic points according to the extracted characteristic pixel coordinates, and solves the space position of the current position of the main vehicle system;
12) after the binocular vision navigator finishes positioning, the main vehicle system is guided to reach the position of a weld joint to be operated, the type of the weld joint is divided into horizontal and vertical, when a horizontal weld joint is welded, the main vehicle system moves along the direction of the horizontal weld joint, and when a vertical weld joint is welded, the main vehicle system moves along the horizontal central path of the vertical weld joint; repeating the two groups of paths to alternately move until the whole welding process is finished;
13) for the edge position of the welding seam, detecting and extracting the information by using a canny edge detection algorithm; the positions of horizontal welding lines and vertical welding lines are detected by using a linear detection algorithm, the positions of the welding lines are obtained by using binocular intersection calculation, the position of the current main vehicle system is identified by using a binocular vision navigator, the position of the welding line is calculated by using stereoscopic vision when the welding is detected to be finished, the motion path of the main vehicle system at the next moment is planned according to the current position, and the main vehicle system is controlled to move to the corresponding position.
Preferably, the specific operation steps of step 2 are as follows:
21) acquiring the contour of the current time-division structured light projected onto a workpiece to be welded by using a visual detection unit, acquiring a coordinate point set of the contour of the current time-division structured light projected onto the workpiece to be welded by using a miniature industrial personal computer, and converting the contour coordinate point set into the coordinate of the multi-degree-of-freedom mechanical arm;
22) the micro industrial personal computer calculates the position of the welding line at the current moment;
23) comparing the position of the welding seam at the current moment with an initial setting position, and if the deviation between the current welding seam position and the initial position exceeds a set threshold value, feeding back the offset to a micro industrial personal computer to control the multi-degree-of-freedom mechanical arm to move by corresponding offset;
24) when welding of the collected welding lines is detected to be finished within a period of time, arc-extinguishing operation is carried out at the moment before the welding is finished, the welding of the current circle is finished, then the step 1 is carried out, the position of the welding line of the next circle is identified, and the main vehicle system is controlled to move to the corresponding position.
Preferably, the specific operation steps of step 3 are as follows:
31) correcting the offset caused by the slippage offset of the driving wheel by using a high-precision code disc A, B to correct the offset X' of the main system in the traveling X direction; by the current x value and the initial setting TxComparing, outputting deviation within a certain X threshold value, compensating the deviation by the mechanical arm, and compensating by the driving wheel when the deviation exceeds the certain X threshold value;
32) the Z-direction offset Z' of the main vehicle system is obtained through the front and rear groups of laser vision sensors A, B of the main vehicle system; the front and the back groups of visual sensors acquire the current position coordinates of the welding seam in real time to obtain the current position Pz of the welding seam acquired by the front and the back groups of visual sensors1(x1,z1)，Pz2(x2,z2) The positions of the front and rear outer contours of the main vehicle system are calculated in real time, and the coordinates of the robot, namely the coordinate Pz ((x) of the central point can be obtained according to the calculation1+z2)/2,(y1+z2) /2), comparing with the initial position, and outputting the current offset as z' if the current offset exceeds a set threshold Tz;
33) setting initial offset as (0, 0, 0), respectively acquiring offsets of the high-precision code disc A, B, the visual detection unit and the laser visual sensor A, B in the X and Z directions in real time, and feeding back the current offsets (X ', 0, Z') to the control platform after the offset in any direction exceeds a threshold value T set in the direction, so as to control the wall-climbing robot to perform corresponding correction.
Preferably, before welding, a visual detection unit is used for identifying and detecting a welding seam, and a corresponding welding process and welding parameters are recommended to the miniature industrial personal computer;
in the welding process, the offset of the welding gun relative to the welding seam is detected by using the visual detection unit, the miniature industrial personal computer is used for calculating data and image information, finally, the deviation information is transmitted to the mechanical arm control cabinet, the deviation is compensated, and the multi-degree-of-freedom mechanical arm is guided to the corresponding accurate welding position for welding.
Preferably, a visual detection unit is used for detecting the welding seam, welding seam characteristic information is obtained according to groove three-dimensional information extraction, and accordingly multilayer and multichannel cloth layer cloth channel planning and process parameter recommendation of each layer and each channel are carried out;
recommending a corresponding welding working mode according to the plate thickness of the workpiece to be welded and the required parameters of the weld leg residual height;
and in the welding process, the position of the welding seam is detected in real time by using the visual detection unit, the offset of the current welding gun relative to the welding seam is calculated according to the relative position of the welding seam and the welding gun, and the multi-degree-of-freedom mechanical arm is controlled to correspondingly correct the current offset.
Due to the adoption of the technical scheme, the invention has the following beneficial effects:
1. the invention adopts the mode of combining the main vehicle system with the auxiliary vehicle system, and solves the problem that the existing arc welding robot cannot meet the welding requirement of the non-standard product production environment.
2. The invention adopts the mode that the vision detection unit in the main vehicle system is matched with the main vehicle climbing frame to be linked with the multi-degree-of-freedom mechanical arm, so that the problems that the teaching mode cannot adapt to deformation in the welding process and workpieces are inconsistent can be solved.
3. The invention adopts the mode of installing the high-precision code disc and the laser vision sensor on the main vehicle wall-climbing frame, thereby solving the problem of low welding quality caused by the deviation of the self weight of the wall-climbing robot from the welding track.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the principles of the invention:
FIG. 1 is a schematic structural diagram of a climbing welding robot based on vision measurement according to the present invention;
FIG. 2 is a first schematic structural diagram of a primary system of the present invention;
FIG. 3 is a schematic structural diagram of a second main system of the present invention;
FIG. 4 is a schematic structural diagram of an auxiliary vehicle system according to the present invention;
FIG. 5 is a flow chart of the operation of the welding method of the present invention;
FIG. 6 is a schematic diagram of a weld path planning according to the present invention.
In the figure: 1. a primary vehicle system; 2. an auxiliary vehicle system; 3. a workpiece to be welded;
11. the main vehicle climbs the wall frame; 12. a binocular vision navigator; 13. a multi-degree-of-freedom mechanical arm; 14. a visual detection unit; 15. a wire feeder; 16. high-precision code disc A; 17. a laser vision sensor A; 18. a welding gun; 19. a laser vision sensor B; 110. high-precision code disc B; 111. a wire reel; 112. a miniature industrial personal computer;
21. an auxiliary vehicle frame; 22. a welding machine; 23. a cooling water tank 24 and a wire feeding barrel; 25. a vision module; 26. an electro-permanent magnetic chuck; 27. a flexible magnetically permeable material; 28. arm switch board.
Detailed Description
The present invention will now be described in detail with reference to the drawings and specific embodiments, wherein the exemplary embodiments and descriptions of the present invention are provided to explain the present invention without limiting the invention thereto.
As shown in fig. 1, an embodiment of the present invention provides a wall climbing welding robot based on vision measurement, including a main vehicle system 1 and an auxiliary vehicle system 2; the main vehicle system 1 is adsorbed on the inner wall of a workpiece 3 to be welded through an electric permanent magnet; as shown in fig. 2 and 3, the main vehicle system 1 includes a main vehicle climbing frame 11, a binocular vision navigator 12, a multi-degree-of-freedom mechanical arm 13, a vision detection unit 14, a wire feeder 15, a wire reel 111, a micro industrial personal computer 112, a high-precision code disc a16, a high-precision code disc B110, a laser vision sensor a17 and a laser vision sensor B19; the main vehicle climbing wall rack 11 is erected on a travelling wheel, and the main vehicle climbing wall rack 11 is provided with a multi-degree-of-freedom mechanical arm 13, a wire feeder 15, a wire disc 111, a micro industrial personal computer 112, a binocular vision navigator 12 and a laser vision sensor A17; the visual detection unit 14 is arranged on the multi-degree-of-freedom mechanical arm 13, and the high-precision code disc A16 and the high-precision code disc B110 are respectively arranged on the driving wheel; the binocular vision navigator 12 and the multi-degree-of-freedom mechanical arm 13 are fixed at the tail end of the chassis of the climbing wall rack 11 of the main vehicle through locking screws, and the binocular vision navigator 12 is used for automatic planning, identification and positioning of a welding path. The wire feeder 15 and the wire reel 111 are respectively fixed on the left side and the right side of the chassis of the main climbing wall frame 11, the micro industrial personal computer 112 controls the wire feeder 15 and the wire reel 111 to continuously and stably provide welding wires for a welding gun, and the welding gun starts arc through the welding machine to weld seams, and the micro industrial personal computer 112 is fixed at the front end of the main climbing wall frame 11 and is mainly used for image recognition and algorithm processing.
As shown in fig. 2 and 3, a welding gun 18 is fixed at the end of the multi-degree-of-freedom mechanical arm 13 and is positioned by inserting a pin; the visual detection unit 14 is fixed on the welding gun 18, and the visual detection unit accurately identifies and tracks the welding seam position by using a 3D visual detection mode, automatically identifies the position deviation and the workpiece dimension error of the welding seam group, and corrects the welding track. The high-precision code disc A16 and the high-precision code disc B110 are respectively installed in the right centers of the left and right driving wheels of the main climbing wall rack 11 and used for monitoring and uploading the slip offset of the driving wheels; the laser vision sensor A17 and the laser vision sensor B19 are respectively installed at the front end and the rear end of the main vehicle climbing wall frame 11 and are vertically and downwards fixedly installed, and the position deviation amount of the main vehicle system is measured through the front image aberration and the rear image aberration.
As shown in fig. 4, the auxiliary vehicle system includes: the auxiliary vehicle comprises an auxiliary vehicle frame 21, a welding machine 22, a cooling water tank 23, a wire feeding barrel 24, a vision module 25, an electric permanent magnetic chuck 26, a flexible magnetic conductive material 27 and a mechanical arm control cabinet 28; the auxiliary vehicle frame 21 is controlled by the plurality of electric permanent magnetic chucks 26 at the bottom to be switched on and off and follow-up and be adsorbed on a curved surface wall, the welding machine 22, the cooling water tank 23, the wire feeding barrel 24 and the mechanical arm control cabinet 28 are all fixed at the top of the auxiliary vehicle frame 21, the welding machine provides an electric appliance of a power supply for welding, the cooling water tank cools equipment during welding, relevant equipment is prevented from being influenced by overhigh welding temperature, the wire feeding barrel provides a spare welding wire for a main vehicle system, the mechanical arm control cabinet is used for executing motion control of a multi-degree-of-freedom industrial mechanical arm, and welding protective gas is directly supplied to a welding gun through a gas. The vision module 25 is arranged at the bottom of the auxiliary vehicle frame 21, monitors the main vehicle system and controls the follow-up of the main vehicle system; the flexible magnetic conducting material 27 is attached to the side face of the auxiliary vehicle frame 21, protects the main vehicle system when demagnetization, abnormity or runaway fall occurs, and ensures that the main vehicle system has certain buffering and can be reliably and stably adsorbed on the side face of the auxiliary vehicle system when falling by virtue of the flexible magnetic conducting material.
When the main car climbing wall machine frame 11 works, the main car climbing wall machine frame 11 of the main car system 1 is adsorbed on the inner wall of a workpiece 3 to be welded in an electro-permanent magnetic adsorption mode, guided to move by two guide wheels at the front end, two groups of motors at the rear end are matched with a driving group to move, and the flatness of the upper surface processing of the chassis of the main car climbing wall machine frame 11 is guaranteed to be within 0.02 mm. The main vehicle system 1 is combined with a multi-degree-of-freedom mechanical arm, and the wall-climbing robot and the welding gun are guided by the binocular vision navigator, the laser vision sensor and the vision detection unit to perform unmanned wall-climbing welding operation on the workpieces to be welded 3 in different areas of a curved surface, so that the welding area can be completely covered; the auxiliary vehicle system 2 carries relevant welding equipment through an auxiliary vehicle frame 21 to follow up with the main vehicle system, dynamically tracks the position of the main vehicle system by means of a vision module at the top, feeds back the position information of the main vehicle to an auxiliary vehicle control system according to natural frequency, lightens the load of the main vehicle system by the mode, increases the flexibility, ensures that welding seams at different height positions can be completely welded, and simultaneously protects the wall climbing robot from being out of control and falling.
As shown in fig. 5, the present invention further provides a welding method of an unmanned climbing welding robot based on vision measurement, comprising the following steps:
And 2, the main vehicle system 1 conducts system environment perception on the operation space by using the binocular vision navigator 12 and positions the position of a welding seam to guide the main vehicle system 1 to the position of a workpiece to be welded, meanwhile, the auxiliary vehicle system 2 dynamically tracks the position of the main vehicle system 1 by depending on a vision module 25 at the top, feeds back the position information of the main vehicle system 1 to the auxiliary vehicle system 2 according to the inherent frequency, and moves according to the rhythm that the auxiliary vehicle system moves once along with the main vehicle system every time the main vehicle system moves one meter. The binocular vision navigator has the main functions of acquiring and sensing environmental information in a three-dimensional space through a camera module, positioning the position of the wall-climbing robot according to the spatial information and inherent characteristics of a welding seam and a workpiece, and guiding the wall-climbing robot to reach a corresponding welding operation path, as shown in fig. 6, the specific operation steps are as follows:
21) the binocular vision navigator 12 carries out preprocessing such as denoising and filtering on the acquired surrounding space environment image information, identifies key feature points of the current position of the preprocessed image, extracts pixel coordinates of the feature points, utilizes internal parameters of the binocular vision navigator 12 to solve the space coordinates of the feature points according to the extracted feature pixel coordinates, and solves the current spatial position of the main vehicle system 1;
22) after the binocular vision navigator 12 finishes positioning, the main vehicle system 1 is guided to reach the position of the welding line to be operated. As shown in fig. 6, after the whole system starts to operate, the main system 1 is mainly guided to reach the corresponding welding position, the welding seam type is mainly divided into two dimensions of the horizontal direction and the vertical direction, the main system 1 mainly moves along the horizontal direction, and there are mainly two basic paths: along the horizontal weld path and the vertical weld horizontal center position path. The overall path of the main system 1 moves along the position of a horizontal welding line, the vertical welding line is welded at the horizontal center position of the vertical welding line in a moving way, and the two groups of paths are repeated to move alternately in the execution process until the whole welding is finished;
23) the method comprises the steps of detecting and extracting the edge position of a welding seam by using a canny edge detection algorithm, detecting the positions of a horizontal welding seam and a vertical welding seam by using a linear detection algorithm, calculating the position of the welding seam by using binocular intersection, mainly identifying the position of a current main vehicle system 1 by using a binocular vision navigator, calculating the position of the welding seam by using stereoscopic vision after welding is detected to be finished, planning the motion path of the main vehicle system 1 at the next moment according to the current position, and controlling the main vehicle system 1 to move to the corresponding position.
31) the contour of the current time line structured light projected onto the workpiece 3 to be welded is collected by means of the visual detection unit 14. The data obtained by the vision detection unit 14 is a coordinate point set of the contour of the linear structured light projected onto the workpiece 3 to be welded at the current moment, and the contour coordinate point set is converted into the robot coordinate;
32) calculating the position of the welding seam at the current moment by utilizing a coordinate point set of the contour of the linear structure light projected onto the workpiece 3 to be welded, which is acquired by the visual detection unit 14;
33) the position of the welding line at the current moment is collected and calculated in real time by using the visual detection unit 14 and is compared with an initial setting position, if the deviation between the current welding line position and the initial position exceeds a set threshold value, the offset is fed back to the control platform, and the control platform controls the mechanical arm to move corresponding offset;
34) when welding of the collected welding line is detected to be finished within a period of time, arc-extinguishing operation is carried out at the moment before welding is finished, welding of the current circle is finished, then step 2 is carried out, the position of the next circle is identified, and the main vehicle system 1 is controlled to move to the corresponding position.
Step 4, in the welding seam process, the main vehicle system deviates along the original planned path due to the slippage and the dead weight of the main vehicle system, the deviation of the main vehicle system needs to be measured at the moment, the deviation of the slippage of the driving wheel is measured through two groups of high-precision code discs A16 and B110 arranged on the driving wheel, the deviation of the main vehicle system relative to the position of a workpiece to be welded is measured through two groups of laser vision sensors A17 and B19 arranged at the front and the rear of the main vehicle system, the main vehicle system is controlled to correspondingly respond by calculating the deviation of the high-precision code discs and the relative relation between the current main vehicle system and the position of the welding seam to be welded, and the deviation is:
41) the offset amount due to the offset amount of the drive wheel slip is corrected by the high-precision disks a16, B110, and the offset amount X' in the main system traveling X direction is corrected. By the current x value and the initial setting TxComparing, outputting deviation within a certain X threshold value, compensating the deviation by the mechanical arm, and compensating by the driving wheel when the deviation exceeds the certain X threshold value;
42) the Z-direction offset Z' of the main vehicle system is obtained through the front and the rear groups of laser vision sensors A17 and B19 of the main vehicle system. The front and the back groups of visual sensors acquire the current position coordinates of the welding seam in real time to obtain the current position Pz of the welding seam acquired by the front and the back groups of visual sensors1(x1,z1)，Pz2(x2,z2) The positions of the front and rear outer contours of the main vehicle system are calculated in real time, and the coordinates of the robot, namely the coordinate Pz ((x) of the central point can be obtained according to the calculation1+z2)/2,(y1+z2) /2), comparing with the initial position, and outputting the current offset as z' if the current offset exceeds a set threshold Tz;
44) setting initial offset as (0, 0, 0), respectively acquiring offsets of the high-precision code discs A16 and B110, the visual detection unit 14 and the laser visual sensors A17 and B19 in X and Z directions in real time, and feeding back the current offset (X ', 0, Z') to the control platform after the offset in any direction exceeds a threshold value T set in the direction, so as to control the wall climbing robot to perform corresponding correction.
Further, before welding, a visual detection unit 14 is used for carrying out identification detection on the welding seam, and a corresponding welding process and welding parameters are recommended to the main control platform; the offset of a welding gun relative to a welding seam is detected by the visual detection unit 14 in the welding process, the miniature industrial personal computer 112 is used for calculating data and image information, finally, the offset information is transmitted to the mechanical arm control cabinet 28, the offset is compensated and the multi-degree-of-freedom mechanical arm 13 is guided to a corresponding accurate welding position for welding, the visual detection unit 14 is used for positioning and identifying the welding seam, and the problems that the horizontal movement of the wall climbing robot deviates from a set track and a teaching mode due to gravity, the deformation in the welding process and the inconsistency of workpieces are not adapted are mainly solved, and the method specifically comprises the following steps:
a. detecting the weld joint by using the visual detection unit 14, extracting according to the three-dimensional information of the groove, obtaining weld joint characteristic information, and accordingly planning the cloth layer and the channel of multiple layers and multiple channels and recommending the process parameters of each layer and each channel;
b. recommending corresponding welding JOB according to the plate thickness of the workpiece to be welded, the required welding leg residual height and other parameters;
c. and in the welding process, the position of the welding seam is detected in real time by using the visual detection unit 14, the offset of the current welding gun relative to the welding seam is calculated according to the relative position of the welding seam and the welding gun, and the multi-degree-of-freedom mechanical arm 13 is controlled to correspondingly correct the current offset.
According to the embodiment, the problems that welding quality cannot be guaranteed and production efficiency is low due to the fact that the climbing wall welding robot performs welding in a mode of combining a remote controller with manual weld joint identification are solved. The unmanned and flexible welding robot can be realized, and the welding robot can be accurately positioned and guided to reach the specified welding seam position.
The present invention is not limited to the above-mentioned embodiments, and based on the technical solutions disclosed in the present invention, those skilled in the art can make some substitutions and modifications to some technical features without creative efforts according to the disclosed technical contents, and these substitutions and modifications are all within the protection scope of the present invention.
Claims (10)
1. The utility model provides an unmanned wall welding robot that climbs based on vision measurement which characterized in that, includes main car system and auxiliary vehicle system, wherein:
the main vehicle system (1) is adsorbed on the inner wall of a workpiece (3) to be welded in an operation space, welding seam information of a binocular vision navigator (12), a laser vision sensor and a vision detection unit (14) is acquired through a miniature industrial personal computer (112), and the miniature industrial personal computer (112) controls a multi-degree-of-freedom mechanical arm (13) to move a welding gun (18) to weld the workpiece to be welded in different curved surface areas in a climbing mode;
the auxiliary vehicle system (2) acquires the position information of the main vehicle system through the vision module (25), controls the auxiliary vehicle system (2) to follow the main vehicle system (1) through the miniature industrial personal computer (112), controls the multi-degree-of-freedom mechanical arm (13) of the main vehicle system to move, and provides power and cooling liquid for the welding gun.
2. The unmanned wall climbing welding robot based on vision measurement according to claim 1, characterized in that the main vehicle system (1) comprises a binocular vision navigator (12), a multi-degree-of-freedom mechanical arm (13), a vision detection unit (14), a wire feeder (15), a wire disc (111), two sets of high-precision code discs, two sets of laser vision sensors and a micro industrial personal computer (112); a binocular vision navigator (12), a multi-degree-of-freedom mechanical arm (13), a wire feeder (15), a wire reel (111), a micro industrial personal computer (112), two groups of laser vision sensors A (17) and B (19) are arranged on a main vehicle climbing wall rack (11), and the main vehicle climbing wall rack (11) is erected on a driving wheel; the laser vision sensor A (17) and the laser vision sensor B (19) are respectively arranged at the front end and the rear end of the main vehicle climbing wall rack (11) and face downwards vertically, and the driving wheels are controlled by a miniature industrial personal computer (112).
3. The unmanned wall climbing welding robot based on vision measurement as claimed in claim 2, characterized in that the vision detection unit (14) is arranged on a multi-degree-of-freedom mechanical arm (13), and two sets of high-precision code disc A (16) and high-precision code disc B (110) are respectively arranged on a driving wheel; the binocular vision navigator (12) and the multi-degree-of-freedom mechanical arm (13) are fixed at the tail end of the chassis of the climbing frame (11) of the main vehicle through locking screws.
4. The unmanned wall climbing welding robot based on vision measurement according to claim 1, characterized in that the auxiliary vehicle system (2) comprises an auxiliary vehicle frame (21), a welding machine (22), a cooling water tank (23), a wire feeding barrel (24), a vision module (25), an electric permanent magnetic chuck (26), a flexible magnetic conductive material (27) and a mechanical arm control cabinet (28); the welding machine (22), the cooling water tank (23), the wire feeding barrel (24) and the mechanical arm control cabinet (28) are all fixed at the top of the auxiliary vehicle rack (21), and the vision module (25) is installed at the bottom of the auxiliary vehicle rack (21); the side wall of the auxiliary vehicle frame (21) is coated with a flexible magnetic conductive material (27).
5. A welding method of an unmanned wall climbing welding robot based on vision measurement is characterized by comprising the following steps:
step 1, a main vehicle system (1) utilizes a binocular vision navigator (12) to sense the system environment of a working space and position a welding seam, the main vehicle system (1) is guided to the position of a workpiece to be welded, and meanwhile, an auxiliary vehicle system (2) controls the auxiliary vehicle system (2) to follow the main vehicle system (1) through a miniature industrial personal computer (112);
step 2, a micro industrial personal computer (112) acquires the welding seam information of a visual detection unit (14), guides the main vehicle system (1) to be linked with the multi-degree-of-freedom mechanical arm (13), walks and welds at the same time, sends welding wires into a welding gun (18) through a wire feeder (15) and a wire disc (111), and starts arcs through a welding machine (22) of an auxiliary vehicle system (2) to weld seams; the cooling water tank (23) continuously cools the welding gun (18);
step 3, in the process of welding the welding seam, measuring the slippage offset of a driving wheel through two groups of high-precision coded disks A (16) and B (110), measuring the position deviation relative to a workpiece to be welded (3) through two groups of laser vision sensors A (17) and B (19), and controlling a main vehicle system to correct the offset by calculating the offset of the two groups of high-precision coded disks and the current deviation of the main vehicle system (1) relative to the position of the welding seam to be welded;
and 4, repeating the steps 1 to 3, and finishing the welding process of the unmanned wall climbing welding robot based on the vision measurement.
6. The welding method of the unmanned wall climbing welding robot based on the visual measurement according to claim 5, wherein the step 1 comprises the following specific operation steps:
11) the binocular vision navigator (12) carries out denoising and filtering preprocessing on the collected surrounding space environment image information, identifies key characteristic points of the current position of the preprocessed image, extracts pixel coordinates of the characteristic points, utilizes internal parameters of the binocular vision navigator (12) to solve the space coordinates of the characteristic points according to the extracted characteristic pixel coordinates, and solves the current spatial position of the main vehicle system (1);
12) after the binocular vision navigator (12) completes positioning, the main vehicle system (1) is guided to reach the position of a weld joint to be operated, the type of the weld joint is divided into horizontal and vertical, when a horizontal weld joint is welded, the main vehicle system (1) moves along the direction of the horizontal weld joint, and when a vertical weld joint is welded, the main vehicle system (1) moves along the horizontal central path of the vertical weld joint; repeating the two groups of paths to alternately move until the whole welding process is finished;
13) for the edge position of the welding seam, detecting and extracting the information by using a canny edge detection algorithm; the positions of horizontal welding lines and vertical welding lines are detected by using a linear detection algorithm, the positions of the welding lines are obtained by using binocular intersection calculation, the position of the main vehicle system (1) at the present moment is identified by using a binocular vision navigator (12), welding is detected to be completed, the position of the welding lines is calculated by using stereoscopic vision, a motion path of the main vehicle system (1) at the next moment is planned according to the present position, and the main vehicle system (1) is controlled to move to the corresponding position.
7. The welding method of the unmanned wall climbing welding robot based on the visual measurement according to claim 5, wherein the step 2 comprises the following specific operation steps:
21) the method comprises the steps that a visual detection unit (14) is used for collecting the outline of line structured light projected onto a workpiece (3) to be welded at the current moment, a miniature industrial personal computer (112) obtains a coordinate point set of the outline of the line structured light projected onto the workpiece (3) to be welded at the current moment, and the coordinate point set of the outline is converted into the coordinate of a multi-degree-of-freedom mechanical arm (13);
22) the micro industrial personal computer (112) calculates the position of the welding line at the current moment;
23) comparing the position of the welding seam at the current moment with an initial setting position, if the deviation between the current welding seam position and the initial position exceeds a set threshold value, feeding back the offset to a micro industrial personal computer (112), and controlling the multi-degree-of-freedom mechanical arm (13) to move by corresponding offset;
24) when welding of the collected welding lines is detected to be finished within a period of time, arc-extinguishing operation is carried out at the moment before the welding is finished, the welding of the current circle is finished, then the step 1 is carried out, the position of the welding line of the next circle is identified, and the main vehicle system (1) is controlled to move to the corresponding position.
8. The welding method of the unmanned wall climbing welding robot based on the visual measurement as claimed in claim 5, wherein the step 3 comprises the following specific operation steps:
31) correcting the offset caused by the slippage offset of the driving wheels by using high-precision code discs A (16) and B (110), and correcting the offset X' of the main system in the X-direction of walking; by the current x value and the initial setting TxComparing, outputting deviation within a certain X threshold value, compensating the deviation by the mechanical arm, and compensating by the driving wheel when the deviation exceeds the certain X threshold value;
32) the Z-direction offset Z' of the main vehicle system is measured by front and rear laser vision sensors A (17) and B (19) of the main vehicle system (1); the front and the back groups of visual sensors acquire the current position coordinates of the welding seam in real time to obtain the current position Pz of the welding seam acquired by the front and the back groups of visual sensors1(x1,z1)，Pz2(x2,z2) Namely the positions of the front and rear outer contours of the main vehicle system (1), two groups of acquisition positions are calculated in real time by utilizing the outer contour position of the main vehicle system (1), and the coordinates of the robot, namely the coordinates of a central point Pz ((x) can be obtained according to the calculation1+z2)/2,(y1+z2) /2), comparing with the initial position, and outputting the current offset as z' if the current offset exceeds a set threshold Tz;
33) setting initial offset as (0, 0, 0), respectively acquiring offsets of the high-precision code discs A (16) and B (110), the visual detection unit (14) and the laser visual sensors A (17) and B (19) in X and Z directions in real time, and feeding back the current offsets (X ', 0, Z') to the control platform after the offsets in any direction exceed a threshold T set in the direction, so as to control the wall climbing robot to perform corresponding correction.
9. The welding method of the unmanned wall climbing welding robot based on the visual measurement as claimed in claim 5, wherein before the welding is started, the visual detection unit (14) is used for carrying out identification detection on the welding seam, and a corresponding welding process and welding parameters are recommended to the miniature industrial personal computer (112);
in the welding process, the offset of the welding gun relative to the welding seam is detected by using the visual detection unit (14), the micro industrial personal computer (112) is used for calculating data and image information, finally, the deviation information is transmitted to the mechanical arm control cabinet (28), the deviation is compensated, and the multi-degree-of-freedom mechanical arm (13) is guided to the corresponding accurate welding position for welding.
10. The welding method of the unmanned wall climbing welding robot based on the visual measurement according to claim 9, characterized in that a visual detection unit (14) is used for detecting the welding seam, the welding seam characteristic information is obtained according to the three-dimensional information extraction of the groove, and accordingly, the cloth layer cloth channel planning of multiple layers and multiple channels and the process parameter recommendation of each layer and each channel are carried out;
recommending a corresponding welding working mode according to the plate thickness of the workpiece to be welded and the required parameters of the weld leg residual height;
in the welding process, the position of the welding seam is detected in real time by using the visual detection unit (14), the offset of the current welding gun relative to the welding seam is calculated according to the relative position of the welding seam and the welding gun, and the multi-degree-of-freedom mechanical arm (13) is controlled to correspondingly correct the current offset.
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